{"id":3505,"date":"2026-03-26T14:45:28","date_gmt":"2026-03-26T13:45:28","guid":{"rendered":"https:\/\/www.sostyres.international\/rover-research-innovazione-nella-ricostruzione-degli-pneumatici\/"},"modified":"2026-03-27T15:19:31","modified_gmt":"2026-03-27T14:19:31","slug":"rover-research-the-first-regenerated-tire-in-the-world","status":"publish","type":"post","link":"https:\/\/www.sostyres.international\/en\/rover-research-the-first-regenerated-tire-in-the-world\/","title":{"rendered":"Rover Research \u2013 The first regenerated tire in the world"},"content":{"rendered":"

[vc_row][vc_column][vc_column_text css_animation=”fadeInUp” css=””]<\/p>\n

A New Industrial Process to Improve Performance, Sustainability, and Efficiency<\/strong><\/p>\n

For decades, tire retreading has been a strategic solution for the heavy-duty transport sector: it extends the life of tire casings, reduces operating costs, and minimizes environmental impact.<\/p>\n

At Sos Tyres International, we are always interested in new technologies in the tire industry, so we visited a facility that has developed a new retreading process<\/strong> capable of directly altering the molecular structure of the rubber, drastically reducing waste, energy consumption, and the amount of material used.<\/p>\n

During the visit, we interviewed the engineer in charge of the project, who guided us through the various production processes: from traditional methods to the new technology developed by the company.[\/vc_column_text][\/vc_column][\/vc_row][vc_row][vc_column][vc_single_image image=”3424″ img_size=”full” alignment=”center” css_animation=”fadeInUp” css=”” el_class=”img-fluid”][\/vc_column][\/vc_row][vc_row][vc_column width=”1\/2″][vc_column_text css_animation=”fadeInUp” css=””]<\/p>\n

Traditional Retreading Processes<\/strong><\/p>\n

 <\/p>\n

Francesco:<\/strong>
\nTo understand the innovation you\u2019ve developed, let\u2019s start with traditional processes. How does tire retreading work today?<\/p>\n

Engineer Silvio Mennella:<\/strong>
\nThere are two main traditional retreading processes: cold retreading and hot retreading.<\/strong> Both share an initial step: casing scraping.<\/p>\n

This operation involves completely removing the worn tread and part of the underlying layer, down to about 1\u20132 millimeters from the carcass\u2019s steel belts.<\/strong><\/p>\n

The stripping is performed using rotating metal blades<\/strong> that cut through the rubber. During this process, a great deal of heat builds up at the point of contact and smoke is generated, because the rubber reaches high temperatures and can undergo partial combustion.<\/p>\n

The removed material becomes rubber scrap<\/strong>, which must be managed as industrial waste. It is not easily reusable in the production process.[\/vc_column_text][\/vc_column][vc_column width=”1\/2″ css=”.vc_custom_1774537218222{padding-top: 60px !important;}”][vc_single_image image=”3461″ img_size=”full” alignment=”center” css_animation=”fadeInUp” css=”” el_class=”img-fluid”][\/vc_column][\/vc_row][vc_row][vc_column width=”1\/2″][vc_column_text css_animation=”fadeInUp” css=””]<\/p>\n

Cold Retreading<\/strong><\/p>\n

Francesco:<\/strong>
\nHow does cold retreading work?<\/p>\n

Engineer Silvio Mennella:<\/strong>
\nAfter the casing is scraped, a special adhesive<\/strong> is applied to it. Next, a pre-molded tread is applied\u2014that is, one that has already been vulcanized and features the final tread pattern.<\/p>\n

The tread is wrapped around the casing, and the tire is placed in a vacuum chamber<\/strong> or autoclave, where the adhesive vulcanizes, bonding the two components together.<\/p>\n

It is called \u201ccold\u201d retreading because the tread is already vulcanized, so the heat is mainly used to activate the adhesive that creates the bond between the two parts.<\/p>\n

This system requires a stock of pre-molded treads,<\/strong> each with different patterns.[\/vc_column_text][\/vc_column][vc_column width=”1\/2″][vc_single_image image=”3527″ img_size=”full” alignment=”center” css_animation=”fadeInUp” css=”” el_class=”img-fluid”][\/vc_column][\/vc_row][vc_row][vc_column width=”1\/2″][vc_column_text css_animation=”fadeInUp” css=””]<\/p>\n

Hot Retreading<\/strong><\/p>\n

Francesco:<\/strong>
\nSo how does hot retreading work?<\/p>\n

Engineer Silvio Mennella:<\/strong>
\nThe hot process is more complex but also more similar to the production of a new tire.<\/strong><\/p>\n

After the casing is scraped, an extruder<\/strong> is used\u2014a machine that melts the unvulcanized rubber and deposits it directly onto the casing.<\/p>\n

In practice:<\/p>\n

the raw rubber enters the extruder
\na screw melts it and pushes it toward the outlet
\nthe material is applied to the carcass, forming a uniform layer<\/p>\n

At this point, the tire is placed in a segmented mold<\/strong>, which closes and imprints the tread pattern.<\/p>\n

The whole assembly remains in the mold for about an hour and a half at approximately 120\u00b0C<\/strong>, the temperature required for the vulcanization process,<\/strong> which transforms the rubber from a plastic material into an elastic one.[\/vc_column_text][\/vc_column][vc_column width=”1\/2″][vc_single_image image=”3531″ img_size=”full” alignment=”center” css_animation=”fadeInUp” css=”.vc_custom_1774619524977{padding-top: 60px !important;}” el_class=”img-fluid”][\/vc_column][\/vc_row][vc_row full_width=”stretch_row” content_placement=”middle” el_class=”full”][vc_column][vc_column_text css_animation=”fadeInUp” css=””]<\/p>\n

Rubber Before and After Vulcanization<\/strong><\/p>\n

Francesco:<\/strong>
\nWhat is the difference between rubber before and after vulcanization?<\/p>\n

Engineer Silvio Mennella:<\/strong>
\nThe difference is enormous.<\/p>\n

Unvulcanized rubber is a plastic, malleable material,<\/strong> similar to modeling clay: if you shape it, it retains its new form.<\/p>\n

After vulcanization, however, it becomes elastic<\/strong>. This process creates chemical bonds between the rubber molecules through sulfur<\/strong>, which imparts elasticity and mechanical strength.[\/vc_column_text][vc_single_image image=”3473″ img_size=”full” alignment=”center” css_animation=”fadeInUp” css=”” el_class=”full-width”][\/vc_column][\/vc_row][vc_row][vc_column width=”1\/2″][vc_column_text css_animation=”fadeInUp” css=””]<\/p>\n

Differences from Traditional Methods<\/strong><\/p>\n

Francesco:<\/strong>
\nWhat is the main difference from traditional methods?<\/p>\n

Engineer Silvio Mennella:<\/strong>
\nThe main drawback is that scraping removes a large amount of material that is still perfectly usable.<\/strong><\/p>\n

When you get close to the carcass plies, a lot of structurally sound rubber is removed. In practice, this breaks down the carcass,<\/strong> only to add large amounts of material back on top.<\/p>\n

Furthermore:<\/p>\n

rubber waste<\/strong> is generated that must be disposed of
\nenergy is consumed<\/strong> for scraping and vulcanization
\na lot of new rubber is used<\/strong>[\/vc_column_text][\/vc_column][vc_column width=”1\/2″][vc_single_image image=”3485″ img_size=”full” alignment=”center” css_animation=”fadeInUp” css=”” el_class=”img-fluid”][\/vc_column][\/vc_row][vc_row][vc_column width=”1\/2″][vc_column_text css_animation=”fadeInUp” css=””]<\/p>\n

The new process developed by Rover Research<\/strong><\/p>\n

Francesco:<\/strong>
\nLet\u2019s now talk about your innovative process. What is the main difference?<\/p>\n

Engineer Silvio Mennella:<\/strong>
\nThe fundamental difference is that we do not destroy the original structure of the tire casing.<\/strong><\/p>\n

In traditional methods, almost the entire tread is removed down to the plies. In our process, however, we remove only the bare minimum,<\/strong> preserving most of the original rubber.<\/p>\n

In many cases, you can still see the original tread pattern because we remove only a few millimeters.<\/strong><\/p>\n

This means we recover most of the original carcass structure<\/strong>, drastically reducing waste.[\/vc_column_text][\/vc_column][vc_column width=”1\/2″][vc_single_image image=”3489″ img_size=”full” alignment=”center” css_animation=”fadeInUp” css=”” el_class=”img-fluid”][\/vc_column][\/vc_row][vc_row][vc_column][vc_column_text css_animation=”fadeInUp” css=””]<\/p>\n

Controlled Devulcanization<\/strong><\/p>\n

Francesco:<\/strong>
\nWhat is the underlying technological principle of this process?<\/p>\n

Engineer Silvio Mennella:<\/strong>
\nAt the heart of the technology is a process of controlled devulcanization of the rubber surface.<\/strong><\/p>\n

Using a system that employs water and a high-energy jet, we are able to break the chemical bonds of sulfur on the rubber surface.<\/strong><\/p>\n

In this way, the surface temporarily returns to a reactive chemical state, allowing the new rubber to bond directly at the molecular level<\/strong> with the existing rubber.<\/p>\n

It is therefore not a simple bonding process: true molecular continuity<\/strong> is created between the old rubber and the new rubber.[\/vc_column_text][vc_row_inner][vc_column_inner][vc_single_image image=”3535″ img_size=”full” alignment=”center” css_animation=”fadeInUp” css=”” el_class=”img-fluid”][\/vc_column_inner][\/vc_row_inner][\/vc_column][\/vc_row][vc_row][vc_column][vc_column_text css_animation=”fadeInUp” css=””]<\/p>\n

A Structural Bond<\/strong><\/p>\n

Francesco:<\/strong>
\nSo is the bond between the materials different from that in traditional processes?<\/p>\n

Engineer Silvio Mennella:<\/strong>
\nExactly.<\/p>\n

In traditional systems, a bond is created between two distinct materials with adhesives.<\/strong><\/p>\n

In our case, however, we obtain a single continuous elastic structure.<\/strong><\/p>\n

The test is simple: if you try to separate the two layers, they do not come apart. Instead, the entire elastic body of the tire deforms.[\/vc_column_text][\/vc_column][\/vc_row][vc_row][vc_column][vc_column_text css_animation=”fadeInUp” css=””]<\/p>\n

A fully circular process<\/strong><\/p>\n

Francesco:<\/strong>
\nFrom an environmental standpoint, what advantages does this technology offer?<\/p>\n

Engineer Silvio Mennella:<\/strong>
\nThe advantages are significant.<\/p>\n

First of all, we drastically reduce waste.<\/strong> The amount of material removed is about 200\u2013300 grams per tire<\/strong>, compared to several kilograms in traditional processes.<\/p>\n

Furthermore:<\/p>\n

the water<\/strong> used is completely filtered and reused<\/strong>
\nthe removed material becomes devulcanized powder<\/strong>
\nthis material can be reused in new compounds or in other industrial applications,<\/strong> such as agriculture due to its high water absorption capacity, or as an additive<\/strong> for the construction industry<\/p>\n

In practice, the process generates almost zero waste<\/strong>.[\/vc_column_text][\/vc_column][\/vc_row][vc_row][vc_column][vc_single_image image=”3450″ img_size=”full” alignment=”center” css_animation=”fadeInUp” css=”” el_class=”img-fluid”][\/vc_column][\/vc_row][vc_row][vc_column][vc_column_text css_animation=”fadeInUp” css=”” el_class=”img-fluid”]<\/p>\n

Applications of Recovered Material<\/strong><\/p>\n

Francesco:<\/strong>
\nCan the recovered material be reused?<\/p>\n

Engineer Silvio Mennella:<\/strong>
\nYes. The powder we obtain is not simply rubber granules: it is devulcanized material,<\/strong> and therefore chemically more reactive.<\/p>\n

It can be used:<\/p>\n

in new tire compounds<\/strong>
\nin modified asphalt<\/strong>
\nin cement<\/strong>
\nin the leather industry<\/strong>, for example for leather surface treatments<\/p>\n

The applications are numerous and offer high added value.[\/vc_column_text][\/vc_column][\/vc_row][vc_row][vc_column][vc_single_image image=”3454″ img_size=”full” alignment=”center” css_animation=”fadeInUp” css=”” el_class=”img-fluid”][\/vc_column][\/vc_row][vc_row][vc_column][vc_column_text css_animation=”fadeInUp” css=””]<\/p>\n

On-Road Performance<\/strong><\/p>\n

Francesco:<\/strong>
\nDo you already have performance data?<\/p>\n

Engineer Silvio Mennella:<\/strong>
\nYes, we\u2019ve conducted comparative tests with new tires.<\/p>\n

In some tests, we mounted a new premium tire<\/strong> and a regenerated tire<\/strong> produced using our process on the same semi-trailer.<\/strong><\/p>\n

The result was very interesting: the mileage was essentially identical.<\/strong><\/p>\n

We currently have about a thousand tires in circulation<\/strong>, and initial results indicate mileage exceeding 100,000 km<\/strong>, with even greater potential.Applications of the recovered material[\/vc_column_text][\/vc_column][\/vc_row][vc_row][vc_column][vc_column_text css_animation=”fadeInUp” css=””]<\/p>\n

Reduction in CO\u2082 Emissions<\/strong><\/p>\n

Francesco:<\/strong>
\nWhat is the environmental impact compared to a new tire?<\/p>\n

Engineer Silvio Mennella:<\/strong>
\nA new truck tire contains about 75 kg of material.<\/strong><\/p>\n

In our case, we use only about 10\u201312 kg of new rubber,<\/strong> while the rest consists of the recovered original casing.<\/p>\n

This means that the carbon footprint is up to eight times lower<\/strong> than that of manufacturing a completely new tire.[\/vc_column_text][\/vc_column][\/vc_row][vc_row][vc_column][vc_column_text css_animation=”fadeInUp” css=””]<\/p>\n

The tire casing can be reused multiple times<\/strong><\/p>\n

Francesco:<\/strong>
\nHow many times can a tire casing be retreaded?<\/p>\n

Engineer Silvio Mennella:<\/strong>
\nHigh-quality tire casings can be retreaded multiple times over their lifespan.<\/strong><\/p>\n

In some cases in the United States, casings have been retreaded three or four times.<\/strong><\/p>\n

This is because the press vulcanization process also helps to rebalance the internal stresses of the structure,<\/strong> returning the material to a more stable state. The heat relaxes the micro-gaps that form around the plies, and this rejuvenates the tire.[\/vc_column_text][\/vc_column][\/vc_row][vc_row][vc_column][vc_single_image image=”3406″ img_size=”full” alignment=”center” css_animation=”fadeInUp” css=”” el_class=”img-fluid”][\/vc_column][\/vc_row][vc_row][vc_column][vc_column_text css_animation=”fadeInUp” css=””]<\/p>\n

The Circular Economy Applied to Tires<\/strong><\/p>\n

Francesco:<\/strong>
\nWhat is the industrial vision behind this project?<\/p>\n

Engineer Silvio Mennella:<\/strong>
\nThe goal is to move tire retreading toward a true circular economy model.<\/strong><\/p>\n

Not only recovering the casing, but also:<\/p>\n

reducing waste
\nreusing the recovered material
\ncutting energy consumption
\ndrastically reducing CO\u2082 emissions<\/p>\n

In this way, the tire becomes a truly regenerable product,<\/strong> with economic and environmental benefits for the entire transportation sector.[\/vc_column_text][\/vc_column][\/vc_row][vc_row][vc_column][vc_video link=”https:\/\/www.youtube.com\/watch?v=-YsfznasxXc” align=”center” css=””][\/vc_column][\/vc_row]<\/p>\n<\/div>","protected":false},"excerpt":{"rendered":"

Interview with engineer Silvio Mennella<\/p>\n","protected":false},"author":1,"featured_media":3502,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"_joinchat":[],"footnotes":""},"categories":[17],"tags":[],"class_list":["post-3505","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-green-en"],"acf":[],"yoast_head":"\nRover Research \u2013 The first regenerated tire in the world - Sos Tyres International<\/title>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/www.sostyres.international\/en\/rover-research-the-first-regenerated-tire-in-the-world\/\" \/>\n<meta property=\"og:locale\" content=\"en_US\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"Rover Research \u2013 The first regenerated tire in the world - Sos Tyres International\" \/>\n<meta property=\"og:description\" content=\"Interview with engineer Silvio Mennella\" \/>\n<meta property=\"og:url\" content=\"https:\/\/www.sostyres.international\/en\/rover-research-the-first-regenerated-tire-in-the-world\/\" \/>\n<meta property=\"og:site_name\" content=\"Sos Tyres International\" \/>\n<meta property=\"article:publisher\" content=\"https:\/\/www.facebook.com\/SOSTYRESINTERNATIONAL\" \/>\n<meta property=\"article:published_time\" content=\"2026-03-26T13:45:28+00:00\" \/>\n<meta property=\"article:modified_time\" content=\"2026-03-27T14:19:31+00:00\" \/>\n<meta property=\"og:image\" content=\"https:\/\/www.sostyres.international\/wp-content\/uploads\/2026\/03\/rr_2-1.gif\" \/>\n\t<meta property=\"og:image:width\" content=\"400\" \/>\n\t<meta property=\"og:image:height\" content=\"400\" \/>\n\t<meta property=\"og:image:type\" content=\"image\/gif\" \/>\n<meta name=\"author\" content=\"sostyres\" \/>\n<meta name=\"twitter:card\" content=\"summary_large_image\" \/>\n<meta name=\"twitter:label1\" content=\"Written by\" \/>\n\t<meta name=\"twitter:data1\" content=\"sostyres\" \/>\n\t<meta name=\"twitter:label2\" content=\"Est. reading time\" \/>\n\t<meta name=\"twitter:data2\" content=\"11 minutes\" \/>\n<script type=\"application\/ld+json\" class=\"yoast-schema-graph\">{\"@context\":\"https:\/\/schema.org\",\"@graph\":[{\"@type\":\"Article\",\"@id\":\"https:\/\/www.sostyres.international\/en\/rover-research-the-first-regenerated-tire-in-the-world\/#article\",\"isPartOf\":{\"@id\":\"https:\/\/www.sostyres.international\/en\/rover-research-the-first-regenerated-tire-in-the-world\/\"},\"author\":{\"name\":\"sostyres\",\"@id\":\"https:\/\/www.sostyres.international\/en\/#\/schema\/person\/f80849ea81f7410c4573ecdc6f285428\"},\"headline\":\"Rover Research \u2013 The first regenerated tire in the world\",\"datePublished\":\"2026-03-26T13:45:28+00:00\",\"dateModified\":\"2026-03-27T14:19:31+00:00\",\"mainEntityOfPage\":{\"@id\":\"https:\/\/www.sostyres.international\/en\/rover-research-the-first-regenerated-tire-in-the-world\/\"},\"wordCount\":1969,\"publisher\":{\"@id\":\"https:\/\/www.sostyres.international\/en\/#organization\"},\"image\":{\"@id\":\"https:\/\/www.sostyres.international\/en\/rover-research-the-first-regenerated-tire-in-the-world\/#primaryimage\"},\"thumbnailUrl\":\"https:\/\/www.sostyres.international\/wp-content\/uploads\/2026\/03\/rr_2-1.gif\",\"articleSection\":[\"Green\"],\"inLanguage\":\"en-US\"},{\"@type\":\"WebPage\",\"@id\":\"https:\/\/www.sostyres.international\/en\/rover-research-the-first-regenerated-tire-in-the-world\/\",\"url\":\"https:\/\/www.sostyres.international\/en\/rover-research-the-first-regenerated-tire-in-the-world\/\",\"name\":\"Rover Research \u2013 The first regenerated tire in the world - 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